Reach-in cooler

ABSTRACT

A preferred embodiment of the reach-in cooler incorporates a roof structure which includes a ceiling and a roof that are spaced from each other to form an air distribution plenum. The air distribution plenum includes an air return inlet and an air distribution outlet, and communicates with air return passage via the air return inlet. Preferably, the air return passage is formed between the back of the cooler and a partition. The refrigerated space of the cooler is disposed below the roof structure and communicates with the air return passage. Additionally, a refrigeration unit, which includes a refrigeration coil and a fan, communicates with the air return passage so that the fan moves air from the refrigerated space, through said air return passage, through the air return inlet and into the air distribution plenum. The air then is directed through the refrigeration coils for delivery through the air distribution outlet and into the refrigerated space for cooling the refrigerated space. Preferably, the partition incorporates air return orifices so that the fan draws air from the refrigerated space through the air return orifices and into the air return passage. Back-to-back configurations and method aspects also are provided.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to refrigerated structures for the display of refrigerated products. More specifically, the present invention relates to a reach-in cooler which provides a refrigerated space free of refrigeration components.

[0003] 2. Description of the Related Art

[0004] Refrigerated cabinets are well known in the retail grocery industry. These devices provide locations for food product display and provide consumer access to refrigerated food products while they maintain the food products at adequately cold temperatures to prevent spoiling. The term “refrigerated” as used herein applies equally to devices for cooling products below room temperature, both at medium temperature (above 0° F.) and at low temperature (below 0° F.).

[0005] Prior art refrigerated cabinets of a reach-in type typically are one-sided cabinets constructed of metal framing surrounded by insulating material and a thin metal protective cladding. Additionally, the cabinets include one or more insulated glass doors mounted on hinges along a display side of the cabinet. So configured, a consumer may open the glass doors and reach into the refrigerated interior of the cabinet and retrieve food products displayed on shelving mounted within the cabinet.

[0006] A typical prior art reach-in cabinet incorporates its refrigeration coil, fan assembly and associated elements, sometimes referred to as refrigeration unit, at the base or in the partition of the cabinet. The refrigeration unit provides a flow of refrigerated air to the interior of the cabinet, thus allowing a proper temperature to be maintained within the cabinet. A refrigeration unit, however, must be defrosted on a routine basis which requires that the refrigeration unit be shut off, thereby depriving the cabinet of the flow of cooling air normally provided by the refrigeration unit. Normally, however, the period of refrigeration unit shut-off due to defrosting is relatively short and does not require that food products be removed from the cabinet due to an associated rise in temperature of the refrigerated interior of the cabinet.

[0007] Typically, repair or maintenance of a prior art refrigerated display cabinet also requires that the refrigeration unit be shut off, and, oftentimes, requires taking the entire cabinet out of service for a prolonged period of time. In these instances, unloading the food products displayed in the cabinet may be necessitated because servicing of the cabinet may last longer than the time that would cause spoilage of the food products displayed in the cabinet. Thus, unless the food products are moved to another refrigerated location, the products may warm, thaw and spoil. Unloading of the food products and placing the products in a suitable refrigerated location usually involves a significant amount of labor and results in the inability to display and sell products from the cabinet until the refrigeration unit is returned to service.

[0008] Since the refrigeration units of some of the prior art reach-in cabinets are housed at the base of the cabinets, a significant amount of labor also may be expended because at least a portion of the food products displayed within such a cabinet must be removed from the cabinet to allow access to the refrigeration unit. Additionally, it may be necessary to clean the cabinet interior prior to performing maintenance or repair on such a refrigeration unit because debris and spilled liquids can accumulate in the base of the cabinet during normal operations. This cleaning process can consume valuable employee labor hours since each cabinet also must be cleaned on a regular basis in order to comply with governmental and industry health standards.

[0009] Therefore, there is a need to provide improved reach-in coolers which address these and other shortcomings of the prior art.

BRIEF SUMMARY OF THE INVENTION

[0010] Briefly described, the present invention is directed to a reach-in cooler for containing refrigerated products. In a preferred embodiment, the reach-in cooler incorporates a roof structure which includes a ceiling and a roof that are spaced from each other to form an air distribution plenum. The air distribution plenum includes an air return inlet and an air distribution outlet, and communicates with air return passage via the air return inlet. Preferably, the air return passage is formed between the back face of the cooler and a partition. The refrigerated space of the cooler is disposed below the roof structure and communicates with the air return passage. Additionally, a refrigeration unit, which includes a refrigeration coil and a fan, communicates with the air return passage so that the fan moves air from the refrigerated space, through said air return passage, through the air return inlet and into the air distribution plenum. The air then is directed through the refrigeration coils for delivery through the air distribution outlet and into the refrigerated space for cooling the refrigerated space. Preferably, the partition incorporates air return orifices so that the fan draws air from the refrigerated space through the air return orifices and into the air return passage.

[0011] In accordance with another aspect of the present invention, a preferred embodiment of the reach-in cooler is configured as a back-to-back cooler formed from two or more single-sided cooler structures that are arranged in a back-to-back configuration with each other. Preferably, a common air return passage is formed between the single-sided cooler structures.

[0012] A preferred method aspect of the present invention includes the steps of: (1) providing first and second cooler structures; (2) arranging the first and second cooler structures in a back-to-back configuration with each other so that a common air return passage is formed therebetween; (3) moving air from the refrigerated spaces of the cooler structures, upwardly through the common air return passage and above ceilings of the cooler structures; (4) cooling the air, and; (5) delivering the cooled air outwardly toward the fronts of the cooler structures and then directing the air downwardly into the refrigerated spaces of the cooler structures. In some embodiments, the method preferably includes the steps of drawing portions of the air delivered into the refrigerated spaces into the common air return passage at various locations along the partitions of the cooler structures, and then drawing additional portions of the air delivered into the refrigerated spaces across the floors of the cooler structures and into the common air return passage.

[0013] Other objects, features and advantages of the present invention will become apparent upon reading the following specification, when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0014] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating principles of the present invention. In the drawings appended hereto, like numerals illustrate like parts throughout the several views.

[0015]FIG. 1 illustrates a perspective view of a preferred embodiment of the present invention.

[0016]FIG. 2 illustrates a cross-sectional end view of the embodiment of FIG. 1, showing detail of the refrigeration unit and representative air flows.

[0017]FIG. 3 illustrates a perspective view of a preferred embodiment of the present invention with duplicate one-sided reach-in coolers arranged in a back-to-back configuration.

[0018]FIG. 4 illustrates a cross-sectional end view of the embodiment of FIG. 3, showing detail of the refrigeration unit and representative air flows.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Reference will now be made in detail to the description of the invention as illustrated in the drawings. As shown in FIGS. 1 and 2, a preferred embodiment of the reach-in cooler 10 of the present invention is configured as a free-standing structure with a display wall or front 12, a rear wall or back 14, opposing side walls 16 and 18, a base 20, and a roof 22. Front 12 typically is formed of a framework which defines one or more display openings 24 for providing access to an interior refrigerated space 28 and which are adapted to receive product access doors 26, preferably formed as thermally insulated glass doors. Being capable of numerous other configurations, front 12, as used herein, refers to that portion of a cooler that provides access to the refrigerated space of the cooler such that a consumer may access products displayed within the cooler by reaching into the front of the cooler. Additionally, side walls 16 and 18 can be covered, such as with cladding, or can be abutted with other coolers.

[0020] Refrigerated space 28 is bounded by front 12, sides 16 and 18, a partition 30, a floor 32, and a ceiling 34, and is sized and shaped for the display and storage of products which typically are placed upon shelves 36 and product racks 38. Typically, shelves 36 and racks 38 are mounted to partition 30 and extend into the refrigerated space 28 toward display face 12. Support for the shelves 36 is provided by a support frame 40 which includes a plurality of vertical framing members 42, a horizontal framing member or beam 44, which preferably interconnects upper ends of the vertical framing members 42, and a plurality of joists 46 extending transversely, outwardly across the beam 44.

[0021] As shown in greater detail in FIG. 2, reach-in cooler 10 incorporates a horse 48 which provides a set of wheels 50 that allow the cooler to be maneuvered during installation and/or repair. A drain pan or tank 52 is affixed to the horse, with the tank 52 and horse 48 forming the base 20 of the cooler. Preferably, tank 52 is provided with a drain 53.

[0022] As shown in the embodiment of FIG. 2, lower ends of the vertical framing members 42 are attached to the upper surface of tank 52. Preferably, the vertical framing members 42 are arranged toward the back 14 of the cooler and are spaced therefrom so that an upper air return passage 54 is formed between back 14 and vertical framing members 42. The upper air return passage 54 also is defined by one or more partition panels 56 which preferably are affixed to the vertical framing members 42. Preferably, each of the partition panels 56 incorporates a pair of holes 57 which are sized and shaped for the insertion of fingers of an operator so that the panels may easily be grasped during installation and/or removal.

[0023] Upper air return passage 54 preferably communicates with a lower air return passage 58 which preferably is formed between floor 32 and the tank 52. Thus, the lower air return passage 58 and the upper air return passage 54 cooperate to provide a corridor through which a flow of air from the refrigerated space 28 may travel as it returns to a refrigeration unit 60, which is mounted above the ceiling 34 of the cooler. A lower edge of each of the partition panels 56 also may be spaced from the floor 32 to provide an enlarged return opening 61 through which return air may flow in order to merge with the return air of the upper air return passage 54.

[0024] Refrigeration unit 60 includes a fan 62 and an evaporator coil 64, with the evaporator coil preferably being oriented between the fan 62 and a front header 66. The refrigeration unit 60 preferably is contained within an air distribution plenum 68 which is bounded by ceiling 34, front header 66, roof 22 and back 14. Refrigeration unit 60 can incorporate various combinations of fans and evaporator coils, including a plurality of fans per coil, as well as a plurality of evaporator coils per fan. Thus, in a cooler with a multi-coiled refrigeration unit, when an evaporator coil 64 needs to be taken out of service, such as for defrosting, repair, etc., cold air may still be produced by the refrigeration unit as air from the fan can be provided to the evaporator coils remaining in service. So configured, food products may be retained within the refrigerated space 28 versus relocating the food products to another refrigerated space during servicing.

[0025] Support frame 40 is sufficiently robust to support the refrigeration unit 60 above and outside the refrigerated space 28 of the cooler and preferably also is structurally sound so as to support the weight of various maintenance personnel and associated equipment who typically will access the refrigeration unit 60 via the roof 22. To provide access to refrigeration unit 60, one or more refrigeration unit access doors 78 are provided on the roof 22 of the cooler. So provided, maintenance personnel may access the refrigeration unit without having to situate themselves and their tools in the consumer aisle ways adjacent the display face of the cooler. Additionally, since the refrigeration unit 60 preferably is located outside and above the refrigerated space 28, food products stored within the refrigerated space of the cooler do not need to be removed in order to provide access to the refrigeration unit.

[0026] As described hereinbefore, air from the refrigerated space 28 is drawn into the lower air return passage 58 and then is directed upwardly up through the upper air return passage 54 and into the air distribution plenum 68. Once in the air distribution plenum 68, the air is drawn into the fan 62 and then is directed across the various cooling coils of the evaporator coil 64 and toward the front header 66. The cold air departing the evaporator coil 64 then is directed downwardly through one or more nozzles 70 to produce a downwardly directed air curtain 72 which is formed from the coldest air of the cooler, e.g. the air departing the evaporator coil 64.

[0027] The air curtain 72 provides an air flow and temperature barrier between the relatively moist, ambient air surrounding the cooler 10 and the relatively cool, dry air within the refrigerated space 28 that functions to inhibit the refrigerated air within the refrigerated space and the ambient air outside the refrigerated space from intermixing, even while the product access doors 26 are open. As shown in FIG. 2, a portion of the air curtain 72 tends to flow downwardly adjacent the inner side of the doors 26 and then enters an inlet 74 of the horizontal air return passage 58. Additional portions of the air of the air curtain 72 are drawn inwardly toward the partition 30 by a series of air return orifices 76 which are formed through the partition 30. The air return orifices 76 allow the fan 62 to exert a drawing force or suction through the orifices 76 and into the refrigerated space, thus urging some of the air from the refrigerated space to flow toward the partition 30, through the orifices and into the upper air return passage 54 for return to the air distribution plenum 68. In order that the cold air departing the nozzles 70 does not reenter the upper air return passage 54 at locations immediately adjacent the fan 62, and thus potentially short-circuiting the circulation of air throughout the refrigerated space 28, e.g. preventing the coldest air of the air curtain 72 from flowing downwardly to the bottom portion of the refrigerated space, orifices 76 preferably are formed through the partition panels 56 at locations which are sufficiently spaced from the nozzles 70.

[0028] As shown in FIG. 3, single sided reach-in cooler embodiments can be arranged in a back-to-back configuration to form a back-to-back reach-in cooler 100. As shown in greater detail in FIG. 4, the back-to-back reach-in coolers 100 preferably are formed by removing back faces (described hereinbefore) of each of the single-sided coolers 10 and then affixing each of the single-sided units together. Once so affixed, the individual upper air return passages of the single-sided units merge to form a unitary, central air return passage 102 which directs return air from each of the refrigerated spaces 28 to a common air distribution plenum 104, which is formed from the air distribution plenums 68.

[0029] Some embodiments of the back-to-back cooler 100 can be constructed with various components utilized in the construction of the single-sided cooler units 10. In particular, the coolers 100 can incorporate the horse, tank, doors and various other components, with the components being incorporated into the cooler 100 in various stages of pre-assembly. Preferably, these back-to-back coolers (FIG. 4) incorporate support frames 110 which generally are configured as T-shaped structures that are spaced from each other along the length of the cooler 100. Each support frame 110 includes a pair of vertical framing members 112 which are spaced from each other so as to form the central air return passage 102, and a joist 114 which preferably is configured to span the entire width of the cooler. Joists 114 preferably are affixed at upper ends of the vertical framing members 112 and serve as supports for the ceiling and the refrigeration unit, described hereinafter.

[0030] The refrigeration unit of the cooler 100 is arranged within the common air distribution plenum 104. Preferably, the refrigeration unit incorporates pairs of evaporator coils 64, with one of the coils of a pair of coils being oriented between the central air return passage and a front header 66 of the cooler, and the other of the coils of the pair of coils being oriented between the central air return passage and the other front header 66. Additionally, the fans 62 of the refrigeration unit preferably are oriented between the evaporator coils 64, such as above the central air return passage 102, for instance, so that the fans direct return air from the central air return passage outwardly through each of the evaporator coils 64 toward the opposed front headers 66 of the cooler. Once cooled by the evaporators, the refrigerated air approaching the headers 66 is directed downwardly through the nozzles 70 to produce air curtains adjacent the opposing display faces of the cooler 100. The downwardly directed air of the air curtains then flows through the respective refrigerated spaces 28 as described hereinbefore. The air from the refrigerated spaces 28 is then ultimately returned to the central air return passage 102 for recirculation through the various coils of the refrigeration unit.

[0031] The foregoing description has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment or embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations, among others, are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly and legally entitled. 

1. A reach-in cooler for containing refrigerated products, comprising: a roof structure, a base, a front and a back; said roof structure having a ceiling and a roof, said ceiling and said roof being spaced from each other and forming an air distribution plenum therebetween, said air distribution plenum having an air return inlet and an air distribution outlet; a partition spaced from said back and forming a first air return passage therebetween, said first air return passage engaging in fluid communication with said air distribution plenum via said air return inlet; a refrigerated space disposed below said roof structure and defined by said ceiling, said base, said front and said partition, said refrigerated space engaging in fluid communication with said first air return passage; a refrigeration unit having a refrigeration coil and a fan, said refrigeration unit engaging in fluid communication with said first air return passage such that said fan moves air from said refrigerated space, through said first air return passage, through said air return inlet and into said air distribution plenum, and then through said refrigeration coils for delivery through said air distribution outlet and into said refrigerated space for cooling said refrigerated space; said partition having air return orifices formed therethrough such that said fan draws air from said refrigerated space through said air return orifices and into said first air return passage.
 2. The reach-in cooler of claim 1 , wherein said partition has a lower end, said lower end being spaced from said base to form a return opening such that said fan draws air from said refrigerated space through said return opening and into said first air return passage.
 3. The reach-in cooler of claim 1 , wherein said base has a tank and a floor spaced from said tank and forming a second air return passage therebetween, said refrigerated space engaging in fluid communication with said second air return passage such that said fan draws air from said refrigerated space through second air return passage and into said first air return passage.
 4. The reach-in cooler of claim 1 , wherein said front has a display opening and a door, said display opening adapted and arranged for providing access to said refrigerated space, said door hingedly mounted to said front and movable between an opened and a closed position, in said closed position said door preventing access through said display opening to said refrigerated space.
 5. The reach-in cooler of claim 4 , wherein said air distribution outlet has a nozzle such that air delivered from said air distribution plenum and into said refrigerated space passes through said nozzle and forms an air curtain extending downwardly adjacent said display opening within said refrigerated space.
 6. The reach-in cooler of claim 1 , wherein said reach-in cooler has a support structure configured for providing structural support thereto, said support structure having a plurality of framing sections, said framing sections being arranged in a spaced relationship with each other, each of said framing sections having first and second vertical framing members and first and second joists, said first and second vertical framing members being spaced from each other and forming said first air return passage, said first and second joists extending outwardly from said first and second vertical framing members toward said front face, said first and second joists being spaced from each other and forming said air distribution plenum.
 7. A reach-in cooler for containing refrigerated products, comprising: first and second cooler structures, each of said cooler structures having a roof structure, a base, a front and a back, said cooler structures being arranged in a back-to-back configuration with each other such that said first cooler defines a first refrigerated space and said second cooler defines a second refrigerated space with a common air return passage disposed between said first and second refrigerated spaces, said first air return passage being defined by first and second partitions, each of said roof structures having a ceiling and a roof spaced from each other and forming an air distribution plenum therebetween such that, in said back-to-back configuration, said air distribution plenums of said first and second coolers engage in fluid communication with each other to form a common air distribution plenum, said common air distribution plenum having an air return inlet and first and second air distribution outlets, said first air distribution outlet being arranged adjacent to said front of said first cooler structure, said second air distribution outlet being arranged adjacent to said front of said second cooler structure; said common air return passage engaging in fluid communication with said common air distribution plenum via said air return inlet; a refrigeration unit having first and second refrigeration coils and a fan disposed therebetween, said first refrigeration coil being arranged above said first refrigerated space, said second refrigeration coil being arranged above said second refrigerated space, said refrigeration unit engaging in fluid communication with said common air return passage such that said fan moves air from said first and second refrigerated spaces, through said common air return passage, through said air return inlet and into said common air distribution plenum, and then through said first and second refrigeration coils for delivery through said first and second air distribution outlets and into said first and second refrigerated spaces for cooling said refrigerated spaces; said first and second partitions having air return orifices formed therethrough such that said fan draws air from said first and second refrigerated spaces through said air return orifices and into said common air return passage.
 8. The reach-in cooler of claim 7 , wherein said base of said first cooler structure has a floor and a first air return passage formed below said floor, said first air return passage engaging in fluid communication with said common air return passage, and wherein said base of said second cooler structure has a floor and a second air return passage formed below said floor, said second air return passage engaging in fluid communication with said common air return passage such that said fan draws air from said first refrigerated space through said first air return passage and into said common air return passage, and said fan air from said second refrigerated space through said second air return passage and into said common air return passage.
 9. The reach-in cooler of claim 7 , wherein said reach-in cooler has a support structure configured for providing structural support thereto, said support structure having a plurality of framing sections, said framing sections being arranged in a spaced relationship with each other, each of said framing sections having first and second vertical framing members and first and second joists, said first and second vertical framing members being spaced from each other and forming said common air return passage, said first and second joists extending outwardly from said first and second vertical framing members toward said fronts of said first and second cooler structures, said first and second joists being spaced from each other and forming said common air distribution plenum.
 10. A method for displaying refrigerated products, comprising the steps of: providing first and second cooler structures, each of said cooler structures having a ceiling, a floor, a front, a back, and a partition spaced form said back, said first cooler defining a first refrigerated space and said second cooler defining a second refrigerated space; arranging said first and second cooler structures in a back-to-back configuration with each other such that a common air return passage is formed therebetween, said common air return passage being defined by said partitions of said first and second cooler structures, moving air from said first and second refrigerated spaces, upwardly through said common air return passage and above said ceilings of said cooler structures; cooling the air, and; delivering the cooled air outwardly toward said fronts of said cooler structures and then downwardly into said first and second refrigerated spaces for cooling said refrigerated spaces.
 11. The method of claim 10 , further comprising the steps of: drawing portions of the air delivered into said first and second refrigerated spaces into said common air return passage at a plurality of distances measured along said partitions from said ceilings, and; drawing additional portions of the air delivered into said first and second refrigerated spaces across said floors of said first and second cooler structures and into said common air return passage.
 12. The method of claim 11 , wherein the step of drawing portions of the air delivered into said first and second refrigerated spaces comprises drawing portions of the air across shelving and into said common air return passage, said shelving extending into said first and second refrigerated spaces from said partitions. 